Vehicular forward camera module with integrated cooling fan

ABSTRACT

A camera module for a vehicular vision system includes a metallic housing having a metallic upper housing portion and a metallic lower housing portion. A camera is accommodated in the housing and includes an imager circuit board having an imager thereat. The camera includes a lens barrel that protrudes through an aperture of the upper housing portion. A primary circuit board is accommodated in the housing and has an image processor that processes image data captured by the camera. A cooling fan is attached at the lower housing portion and directs airflow between heat dissipating fins of an outer side of the housing, with the heat dissipating fins being in thermal conductive connection via a thermal element with the image processor. The camera module is configured to be disposed at a vehicle windshield so as to have a field of view through the windshield and forward of the vehicle.

CROSS REFERENCE TO RELATED APPLICATIONS APPLICATION

The present application is a 371 U.S. national stage entry of PCTApplication No. PCT/US2020/015306, filed Jan. 28, 2020, which claims thefiling benefits of U.S. provisional application Ser. No. 62/797,469,filed Jan. 28, 2019, which is hereby incorporated herein by reference inits entirety.

FIELD OF THE INVENTION

The present invention relates generally to a vehicle vision system for avehicle and, more particularly, to a vehicle vision system that utilizesa windshield mounted forward viewing camera at a vehicle.

BACKGROUND OF THE INVENTION

Use of imaging sensors in vehicle imaging systems is common and known.Examples of such known systems are described in U.S. Pat. Nos.9,896,039; 9,871,971; 9,596,387 and/or 9,487,159, which are herebyincorporated herein by reference in their entireties. Heat is generatedduring operation of the cameras, and heat dissipating fins or the likeare typically used to dissipate heat.

SUMMARY OF THE INVENTION

The present invention provides a driver assistance system or visionsystem or imaging system for a vehicle that utilizes a windshieldmounted forward viewing camera module having a camera that capturesimage data representative of images of scenes exterior of the vehicle,and provides a cooling fan assembly that is integrated in the cameramodule to force cooling air over one or more parts of the camera moduleto enhance cooling of the camera module during operation of the camera.

These and other objects, advantages, purposes and features of thepresent invention will become apparent upon review of the followingspecification in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a vehicle with a vision system thatincorporates a windshield mounted forward viewing camera module inaccordance with the present invention;

FIG. 2 is a top plan view of the camera module;

FIG. 3 is a rear perspective view of the camera module, showing theintegrated cooling fan assembly at an underside of the camera module;

FIG. 4 is a bottom plan view of the camera module, with the housingshown in phantom to show interior details of the camera module;

FIG. 5 is a top plan view of the circuit board of the camera module;

FIG. 6 is a plan view of the cooling fan assembly;

FIG. 7 is a side elevation of the cooling fan assembly;

FIG. 8 is an upper perspective view of another camera module of thepresent invention;

FIG. 9 is a lower perspective view of the camera module of FIG. 8;

FIG. 10 is a rear perspective view of the camera module of FIG. 8; and

FIG. 11 is an exploded view of the camera module of FIG. 8.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

A vehicle vision system and/or driver assist system and/or objectdetection system and/or alert system operates to capture images exteriorof the vehicle and may process the captured image data to display imagesand to detect objects at or near the vehicle and in the predicted pathof the vehicle, such as to assist a driver of the vehicle in maneuveringthe vehicle in a rearward direction. The vision system includes an imageprocessor or image processing system that is operable to receive imagedata from one or more cameras and provide an output to a display devicefor displaying images representative of the captured image data.Optionally, the vision system may provide display, such as a rearviewdisplay or a top down or bird's eye or surround view display or thelike.

Referring now to the drawings and the illustrative embodiments depictedtherein, a vision system 10 for a vehicle 12 includes at least oneexterior viewing imaging sensor or camera 14, such as a forward viewingimaging sensor or camera, which may be disposed at and behind thewindshield 16 of the vehicle and viewing forward through the windshieldso as to capture image data representative of the scene occurringforward of the vehicle (FIG. 1). Optionally, the system may includemultiple exterior viewing imaging sensors or cameras, such as a forwardviewing camera at the front of the vehicle, and a sideward/rearwardviewing camera at respective sides of the vehicle, and a rearwardviewing camera at the rear of the vehicle, which capture images exteriorof the vehicle. The camera or cameras each include a lens for focusingimages at or onto an imaging array or imaging plane or imager of thecamera. Optionally, the forward viewing camera may be disposed at thewindshield of the vehicle and view through the windshield and forward ofthe vehicle, such as for a machine vision system (such as for trafficsign recognition, headlamp control, pedestrian detection, collisionavoidance, lane marker detection and/or the like). The vision system 10includes a control or electronic control unit (ECU) or processor that isoperable to process image data captured by the camera or cameras and maydetect objects or the like and/or provide displayed images at a displaydevice for viewing by the driver of the vehicle. The data transfer orsignal communication from the camera to the ECU may comprise anysuitable data or communication link, such as a vehicle network bus orthe like of the equipped vehicle.

Heat is generated during operation of the camera, such that, withoutenhanced cooling, maximum operating temperatures at the camera and/orassociated electronics may be exceeded. For instance, the imagersemiconductor junction temperature has to be below a thresholdtemperature to ensure necessary image quality. The camera module 14includes an integrated active cooling fan assembly 18 that is attachedat the lower outside surface of the lower housing cover 20 and thatoperates to force air over and around the camera module's body orhousing to enhance cooling of the camera during operation.

In the illustrated embodiment, the camera module 14 includes a housing21 (e.g., a metal or metallic housing) comprising an upper housingportion 22 (e.g., a metal or metallic upper housing portion) and thelower housing portion 20 (e.g., a metal or metallic lower housingportion), with a camera 24 partially disposed in the housing. The camera24 comprises an imager circuit board having an imager thereat, andfurther comprises a lens barrel (accommodating a lens) that protrudesthrough an aperture of the upper housing portion (as shown in FIG. 2).The camera module includes a main or principle or primary circuit board26 (as shown in FIG. 5) disposed in the housing, with the primarycircuit board comprising an image processor 28 that processes image datacaptured by the camera (with the imager circuit board being electricallyconnected to the main circuit board via a flexible connector, such as aflexible ribbon cable or the like, whereby image data captured by thecamera is provided to the primary or main circuit board via the flexibleconnector). Because of the amount of heat typically generated by thecircuitry of the circuit boards during operation of the camera (andparticularly the heat generated by the image processor of the primarycircuit board during operation of the camera), the cooling fan assemblyis disposed at the lower housing portion such that, when an electricallypowered motor of the cooling fan assembly is electrically powered, theelectrically powered motor rotatably drives a plurality of fan bladesabout an axis of rotation such that the cooling fan directs airflow ontoand along heat dissipating fins of the camera housing, such as at anexterior side of the lower housing portion. The heat dissipating finsare at least in part present at an outer-side location at the outer sideof the lower housing portion that coincides with or is juxtaposed withthe inner-side location of a thermal element (such as a thermallyconductive paste or grease or the like) that thermally conductivelyconnects the image processor with the inner side of the lower housingportion. Thus, the image processor is in thermally conductive connectionwith the heat dissipating fins via the thermal element and a wallthickness (of the lower wall or structure) of the lower housing portionat the location where the thermal element is disposed.

For example, the cooling fan assembly 18 includes a first exit duct 18 athat, when the motor of the cooling fan assembly is electricallypowered, directs airflow between and along heat dissipating fins 20 a(FIGS. 3 and 4) at the lower housing portion 20 that are at or near orthermally conductively connected to the processor 28. The thermalelement or paste or grease may interface or thermally conductivelyconnect the image processor with the inner or upper surface or side ofthe lower housing portion and thus with the heat dissipating fins 20 aat the exterior or outer lower surface or side of the lower housingportion to enhance heat transfer from the processor. The cooling fanassembly comprises a low profile cooling fan assembly that does notprotrude beyond the height of the heat dissipating fins at the outerside of the lower housing portion. The first exit duct 18 a directs airat an end of and in a direction generally parallel to the heatdissipating fins 20 a, such that the air moves along channels betweenadjacent fins to enhance cooling of the fins and thus of the cameramodule.

The cooling fan assembly also includes a second exit duct 18 b (FIG. 3)that, when the motor of the cooling fan assembly is electricallypowered, directs airflow between and along rear heat dissipating fins 19(FIGS. 3 and 4) at an outer side of a rear portion of the housing 21(such as at a rear part of the upper housing portion and/or a rear partof the lower housing portion) that are at or near or thermallyconductively connected to the imager circuit board. For example, athermal element or paste or grease may interface or thermallyconductively connect the imager circuit board and the imager with therear portion of the housing such as an inner surface or side of the rearportion of the housing and thus with the heat dissipating fins 19 (whichare at least in part present at an outer-side location at the outer sideof the rear housing portion that coincides with or is juxtaposed withthe inner-side location of the thermal element that thermallyconductively connects the imager circuit board with the interior side ofthe rear housing portion) to enhance heat transfer from the imagercircuit board. Thus, the imager circuit board is in thermally conductiveconnection with the rear heat dissipating fins via the thermal elementand a wall thickness (of the lower wall or structure) of the rearportion of the housing at the location where the thermal element isdisposed. The second exit duct 18 b directs air at an end of and in adirection generally parallel to the heat dissipating fins 19, such thatthe air moves along channels between adjacent fins to enhance cooling ofthe fins and thus of the camera module.

As shown in FIGS. 2-4, the cooling fan assembly 18 comprises a lowprofile device that is integrated with the camera module. As shown, thecooling fan assembly is attached at the lower side or outer surface ofthe lower housing 20 of the camera module 14. The cooling fan assemblydraws air in at its lower side (such as at one or more inlet vents oropenings at the lower part of the cooling fan assembly) and forces airthrough one or more exit ports or ducts toward targeted regions of thecamera module to enhance or optimize cooling of the camera module (withthe targeted regions optionally having heat dissipating fins orstructure to further enhance or optimize the cooling of the cameramodule).

In the illustrated embodiment, the first exit port or duct 18 a (FIG. 6)of the cooling fan assembly directs airflow onto and along heatdissipating fins of the camera module that are at or near or in contactwith the processor 28 at the main circuit board 26 of the camera module.Thus, the cooling fan provides enhanced cooling of the heat dissipatingfins of the camera module to enhance the dissipation of heat generatedby the processor during operation of the camera.

The second exit port or duct 18 b of the cooling fan assembly directsairflow onto and along the rear surface of the camera module to cool theimager and imager circuit board of the camera 26 disposed at thehousing. For example, heat dissipating fins may be provided at the rearof the camera housing at or near or in thermal conductive contact withthe imager circuit board or elements thereof. The cooling fan duct 18 bdirects airflow onto/into and along the heat dissipating fins of thecamera module to enhance the dissipation of heat generated by the imagerand camera circuitry during operation of the camera. As shown in FIGS. 3and 7, the second exit port or duct 18 b directs the air 90 degrees (orother suitable angle, such as an angle greater than 45 degrees, toaccommodate the shape or curvature of the camera housing) from along thebottom of the camera housing to along the rear of the camera housing(such as at a rear part of the upper housing portion and/or a rear partof the lower housing portion).

The cooling fan assembly comprises a self-contained unit or module thatincludes the motor, fan blades and housing and exit ducts, whereby thecooling fan assembly is mounted at the lower housing portion of thecamera module as a unit. The size and shape of the cooling fan assemblyis selected based at least in part on the size and shape of the cameramodule housing and the location and configuration of the heatdissipating fins. For example, the length of the camera module ispreferably less than 100 mm, more preferably less than 80 mm, and morepreferably less than 60 mm (shown, for example, as 77 mm in FIG. 2),while the width of the camera module is preferably less than 125 mm,more preferably less than 115 mm, and more preferably less than 105 mm(shown, for example, as 110 mm in FIG. 2). The fan assembly may have awidth and length of less than 45 mm, preferably less than 30 mm, such asless than 25 mm (shown, for example, with a width of 30 mm in FIG. 6).The fan assembly may comprise a low profile fan assembly having athickness that is preferably less than 12 mm, more preferably less than7.5 mm, such as less than 5 mm (shown, for example, with a thickness of6 mm in FIG. 7). The air flow generated or output by the fan assemblymay be at a flow rate at least 0.7 cubic feet per minute (CFM), with thelower exit port (that directs air flow along and between the lower heatdissipating fins) output air at a flow rate of at least 0.2 CFM,preferably at least 0.3 CFM, and more preferably at least 0.5 CFM (suchas, for example, 0.35 CFM as shown in FIG. 3), and with the rear exitport (that directs air flow along and between the rear heat dissipatingfins) output air at a flow rate of at least 0.5 CFM, preferably at least0.6 CFM, and more preferably at least 0.6 CFM (such as, for example,0.53 CFM as shown in FIG. 3). The design and configuration of thecooling fan assembly can be adapted to provide desired flow rates at andalong and between the respective heat dissipating fins.

As shown in FIG. 3, the exit ports 18 a, 18 b of the cooling fanassembly have their openings at an entrance to the respective heatdissipating fins, such that the air that is radially exiting the fan atthe ports flows into and along and between the heat dissipating fins. Inthe illustrated embodiment, the heat dissipating fins are generally thesame length and terminate along a generally linear outlet port. However,the fins may be different lengths, with the ends of the heat dissipatingfins forming a curve or other shape that generally corresponds to acurve or shape of the respective outlet port of the cooling fanassembly.

In the illustrated embodiment of FIGS. 2, 3, 6 and 7, the cooling fanassembly is configured to direct air radially out from the fan blades sothat air is directed into passageways or flow paths defined at least inpart by the heat dissipating fins and that receive the air flow atlocations that are radially outboard from the fan blades. Optionally,however, the cooling fan assembly may be configured to direct airaxially into or onto cooling fins or air flow paths.

For example, and such as shown in FIGS. 8-11, a camera module 114includes a housing 121 comprising an upper housing portion or cover 122(e.g., a metal upper housing portion or cover) and a lower housingportion or cover 120 (e.g., a metal lower housing portion or cover),with a camera 124 partially disposed in the housing. The camera module114 includes a main or principle or primary circuit board 126 disposedin the metal housing, with the primary circuit board comprising an imageprocessor that processes image data captured by the camera (with theimage data captured by the camera being provided to the primary circuitboard via a flexible connector, such as a flexible ribbon cable or thelike). As can be seen with reference to FIG. 11, the lens barrel of thecamera 124 is non-parallel to and forms an acute upward angle with theplane of the primary circuit board 126. The camera module furtherincludes an integrated active cooling fan assembly 118 that is attachedat the lower outside surface of the lower housing portion 120 and thatoperates (via electrical powering of a motor 118 a of the cooling fanassembly that rotatably drives a plurality of fan blades 118 b) to forceair toward the camera module's body or housing to enhance cooling of thecamera during operation.

Referring to FIG. 9, the cooling fan assembly 118, when the motor isoperated, directs air flow axially (in a direction parallel to the axisof rotation of the fan blade) toward the lower surface of the camerahousing or lower housing cover 120, where the air may flow along heatdissipating fins 120 a at the lower housing portion 120 (such as alongand within channels defined between adjacent fins) that are at or nearor thermally conductively connected to the processor so as to enhancecooling of the camera module during operation. A thermal element 130(such as a thermally conductive paste or grease or the like) mayinterface or thermally conductively connect the image processor at theprimary circuit board 126 with the inner or upper side or surface of thelower housing portion 120 and thus with the heat dissipating fins 120 aof the lower housing portion 120 to enhance heat transfer from theprocessor. The heat dissipating fins 120 a are at least in part presentat an outer-side location at the outer side of the lower housing portion120 that coincides with or is juxtaposed with the inner-side location ofthe thermal element 130 that thermally conductively connects the imageprocessor with the inner side of the lower housing portion.

The cooling fan assembly 118 may also direct air flow into a passagewayalong the rear of the camera housing (such as along and within channelsdefined between adjacent fins of the heat dissipating fins 119 at a rearportion of the housing, such as at a rear part of the upper housingportion and/or a rear part of the lower housing portion) that are at ornear or thermally conductively connected to the imager circuit board.Another thermal element 132 (such as a thermally conductive paste orgrease or the like) may interface or thermally conductively connect theimager circuit board 124 a of the camera 124 with an inner surface orside of the rear housing portion and thus with the heat dissipating fins119 of the housing to enhance heat transfer from the imager circuitboard. The rear heat dissipating fins 119 are at least in part presentat an outer-side location at the outer side of the rear portion of thehousing that coincides with or is juxtaposed with the inner-sidelocation of where the thermal element 132 thermally conductivelyconnects the imager circuit board with the inner side of the rearportion of the housing.

The air flow path and/or heat dissipating fins may be connected with oraligned or thermally connected to heat dissipating fins 122 a at theupper housing portion 122 to further enhance cooling of the cameramodule. Optionally, a thermal element 134 (such as a thermallyconductive paste or grease or the like) may interface or thermallyconductively connect circuitry or components of the primary circuitboard 126 to a lower or inner surface or side of the upper housingportion 122.

As shown in FIGS. 9 and 10, the cooling fan assembly has a housingportion 118 c that circumscribes the fan blades 118 b and includesattachment structure or flanges for attaching the cooling fan assemblyat the lower housing portion of the camera module. The cooling fanhousing portion 118 c has an air inlet end and an air outlet or exitend, with its output or exit end (the end of the fan structure thatfaces the camera housing) at entrances to the respective heatdissipating fins, such that the air axially exiting the fan flowstowards the lower camera housing and is diverted along and between theheat dissipating fins. In the illustrated embodiment, the lower heatdissipating fins 120 a are formed with shallower fin portions (finportions that protrude a lesser amount from the outer surface of thelower housing portion than deeper fin portions) at the ends where thecooling fan assembly is mounted, such that air output by the fan flowsinto and along and between the heat dissipating fins along the lowerhousing portion (and between the output of the fan and the outer surfaceof the lower housing portion). Likewise, the rear heat dissipating fins119 are formed with fin portions at the lower outer surface of the lowerhousing portion that are generally the same depth as the shallower finportions of the lower heat dissipating fins, such that air output by thefan flows into and along and between the heat dissipating fins along thelower housing portion (and between the output of the fan and the outersurface of the lower housing portion) and into and along and between therear heat dissipating fins at the rear portion of the housing.

The shallower fin portions of the lower heat dissipating fins and thelower portions of the rear dissipating fins may be configured so thattheir lower edges are generally co-planar such that the cooling fanassembly mounts to the lower housing portion with the output area of thefan at the generally planar construction provided by the fin portions.As can be seen with reference to FIGS. 9 and 10, the cooling fanassembly attaches to the lower housing portion via a plurality offasteners (such as, for example, three threaded fasteners or screws thatare threaded into threaded bores or apertures at the lower housingportion), with air flow from the cooling fan (when the motor iselectrically operated) being directed along and between the heatdissipating fins 119, 120 a, and not elsewhere (e.g., the areas wherethe fins 119 or 120 a are not located are sealed or blocked so that airflow generated by the fan does not escape and is instead used to coolthe heat dissipating fins and the camera module.

The deeper fin portions of the lower heat dissipating fins 120 a (thatprotrude a greater amount from the outer surface of the lower housingportion than shallower fin portions) are configured to provide enhancedcooling of the camera module and may be of different lengths along theouter surface so that the ends of the deeper portions of the fins form acurvature or shape that generally corresponds with the curvature orshape of the cooling fan assembly. The output end of the fan assemblythus is disposed over an end or entry portion of the lower heatdissipating fins (at the shallower fin portions) and over an end orentry portion of the rear heat dissipating fins (with the axiallyflowing air flowing in a direction along the rear heat dissipating finsalong the rear portion of the housing), so that the air flow that isaxially output by the fan flows into and along and between therespective heat dissipating fins.

Optionally, the lower housing portion may be constructed with divertingfins or structure that diverts a desired amount or portion of the outputair flow into and along and between the respective heat dissipatingfins. For example, the diverting construction may be centrally locatedat the output end of the fan to divert generally equal parts of theoutput air flow to each set of heat dissipating fins, or the divertingconstruction may be more towards the rear heat dissipating fins so as todivert more of the output air flow into and along the lower heatdissipating fins, so as to provide enhanced cooling of heat generated bythe imager processor during operation of the camera module.

The cooling fan assembly includes a connecting portion 118 d thatattaches at the lower surface of the lower housing portion 120, and thatmay provide for electrical connection (such as via a multi-pin connector118 e (FIG. 11) that plugs into or otherwise electrically connects tocorresponding pins or terminals of or at the primary circuit board) tocircuitry of the camera module when the cooling fan assembly is mountedor attached at the lower housing portion of the camera module. Thecooling fan assembly may also include alignment pins or structure 118 f(FIG. 11) to align the cooling fan with the camera connector and withthe mounting structure as the cooling fan assembly is moved into placeat the lower housing portion of the camera module. Thus, when the cameramodule is installed in the vehicle and electrically connected to thevehicle power source (such as via a multi-pin connector 115 of thecamera module electrically connecting to a plug or socket connector of avehicle wire harness), the cooling fan motor 118 a is electricallycontrolled or powered or operated to cool the camera module duringoperation of the camera module, such as when temperature at the cameramodule exceeds a threshold level, such as discussed below.

The cooling fan assembly 118 comprises a self-contained unit or modulethat includes the motor, fan blades and housing, whereby the cooling fanassembly is mounted at the lower housing portion of the camera module asa unit. The cooling fan housing circumscribes the fan blades and motor(providing a cylindrical air passageway from an inlet end of the coolingfan to an outlet end of the cooling fan) and provides mounting structurefor attaching the cooling fan assembly at the lower housing portion ofthe camera module).

The cooling fan assembly is thus attached (such as via two or morethreaded fasteners or other external connection) at the camera module sothat it can be removed and replaced or serviced without need forreplacing the front camera module. The cooling fan assembly and thecamera module may be configured such that electrical connection of themotor of the cooling fan assembly is made to circuitry of the cameramodule when the cooling fan assembly is attached at the lower housingportion. For example, electrical leads from the circuit board orelectrical connector of the camera module may have terminals or contactsat the lower housing portion where the cooling fan assembly is mounted,such that electrical connection to the cooling fan assembly is made whenthe fan is attached or mounted at the lower housing portion. Theelectrical connection may provide electrical power and/or control to themotor of the cooling fan assembly via the circuitry of the camera modulewhen the camera module is electrically connected to the vehicle powersource (such as via a wire harness or the like). The lower housingportion of the camera module may include a socket or recess forreceiving a portion of the integrated cooling fan assembly in itsmounted or attached position. Optionally, the lower housing portion mayinclude guide pins or the like for accurately positioning the coolingfan assembly (e.g., with respect to the terminals or contacts at thelower housing portion) as the cooling fan assembly is positioned at andattached or mounted at the lower housing portion.

The cooling fan assembly may comprise a DC brushless motor with a 5Voperating voltage, and may be pulse-width modulation (PWM) controlled.The cooling fan assembly may have a starting voltage of around 4 VDC andmay have an operating current of 183 mA and a rated power consumption of0.92 Watts. The cooling fan assembly, when the motor is electricallypowered, may generate up to around 1.18 CFM airflow (or more) whenoperating in the range of around 6,300 RPM to around 11,700 RPM (9000RPM+/−30 percent). The operating temperature range may be around 0degrees C. to around 85 degrees C., with a storage temperature range ofaround −40 degrees C. to around 90 degrees C. In a situation where thefan is locked by an external force while being electrically powered, anincrease in coil temperature of the motor is prevented by temporarilyturning off the electrical power to the fan motor. The fan mayautomatically restart when the locked rotor condition is released.

The camera housing includes vent openings and the cooling fan assemblyincludes channels or ducts that direct air flow (generated when the fanmotor is electrically powered) at cooling fins or components of thecamera module to optimize airflow of the fan as well as to supportnatural convection around the camera module. With respect to the coolingfan assembly 118, the intake opening is at the end of the cooling fanassembly distal from the end of the assembly that interfaces with orattaches at the lower housing portion of the camera module, and thusallows for greater air intake when the motor is powered to drive/rotatethe fan blades. Optionally, the housing of the cooling fan assembly mayinclude structure (see FIG. 10) over the motor and fan blades to preventcontact of the fan blades, such as during assembly and installation ofthe camera module.

The cooling fan motor may comprise a variable speed fan motor that iscontrolled, e.g., by the control or controller or electronic controlunit (ECU) or processor or the like, with a PWM line. The controllerincludes control circuitry and associated software. The PWM duty cyclemay be software (SW) controlled, based on one or more inputs, such as,for example, an input based on an output of a vehicle ambienttemperature sensor (that provides a temperature at or near or indicativeof the temperature at the camera module), an input based on an output ofa vehicle ambient light sensor (to detect sunload and thus to provide anoutput that is indicative of temperature at the windshield and cameramodule), and an input based on an output of one or more internaltemperature sensors at more critical components. The fan may operateonly with the necessary load and speed, in order to improve lifetimerequirements based on targeted device under test (DUT) thermal missionprofile.

Optionally, other cooling elements or devices may also or otherwise beimplemented to cool the camera module during operation. For example, aPeltier element may be disposed at some components to increase thermaldissipation. Optionally, the camera module may include integrated liquidcooling to enhance heat dissipation away from the camera module.Optionally, a cooling fan assembly may be disposed in the vehicleseparate from the camera module, whereby a channel or duct guides anddirects airflow from the separate cooling fan assembly to the cameramodule.

The camera comprises a forward viewing camera, such as disposed at thewindshield, and optionally at a windshield electronics module (WEM) orthe like. The forward viewing camera may utilize aspects of the systemsdescribed in U.S. Pat. Nos. 9,896,039; 9,871,971; 9,596,387; 9,487,159;8,256,821; 7,480,149; 6,824,281 and/or 6,690,268, which are all herebyincorporated herein by reference in their entireties.

The camera or sensor may comprise any suitable camera or sensor.Optionally, the camera may comprise a “smart camera” that includes theimaging sensor array and associated circuitry and image processingcircuitry and electrical connectors and the like as part of a cameramodule, such as by utilizing aspects of the vision systems described inInternational Publication Nos. WO 2013/081984 and/or WO 2013/081985,which are hereby incorporated herein by reference in their entireties.

The system includes an image processor operable to process image datacaptured by the camera or cameras, such as for detecting objects orother vehicles or pedestrians or the like in the field of view of one ormore of the cameras. For example, the image processor may comprise animage processing chip selected from the EYEQ family of image processingchips available from Mobileye Vision Technologies Ltd. of Jerusalem,Israel, and may include object detection software (such as the typesdescribed in U.S. Pat. Nos. 7,855,755; 7,720,580 and/or 7,038,577, whichare hereby incorporated herein by reference in their entireties), andmay analyze image data to detect vehicles and/or other objects.Responsive to such image processing, and when an object or other vehicleis detected, the system may generate an alert to the driver of thevehicle and/or may generate an overlay at the displayed image tohighlight or enhance display of the detected object or vehicle, in orderto enhance the driver's awareness of the detected object or vehicle orhazardous condition during a driving maneuver of the equipped vehicle.

The vehicle may include any type of sensor or sensors, such as imagingsensors or radar sensors or lidar sensors or ultrasonic sensors or thelike. The imaging sensor or camera may capture image data for imageprocessing and may comprise any suitable camera or sensing device, suchas, for example, a two dimensional array of a plurality of photosensorelements arranged in at least 640 columns and 480 rows (at least a640×480 imaging array, such as a megapixel imaging array or the like),with a respective lens focusing images onto respective portions of thearray. The photosensor array may comprise a plurality of photosensorelements arranged in a photosensor array having rows and columns.Preferably, the imaging array has at least 300,000 photosensor elementsor pixels, more preferably at least 500,000 photosensor elements orpixels and more preferably at least 1 million photosensor elements orpixels. The imaging array may capture color image data, such as viaspectral filtering at the array, such as via an RGB (red, green andblue) filter or via a red/red complement filter or such as via an RCC(red, clear, clear) filter or the like. The logic and control circuit ofthe imaging sensor may function in any known manner, and the imageprocessing and algorithmic processing may comprise any suitable meansfor processing the images and/or image data.

For example, the vision system and/or processing and/or camera and/orcircuitry may utilize aspects described in U.S. Pat. Nos. 9,233,641;9,146,898; 9,174,574; 9,090,234; 9,077,098; 8,818,042; 8,886,401;9,077,962; 9,068,390; 9,140,789; 9,092,986; 9,205,776; 8,917,169;8,694,224; 7,005,974; 5,760,962; 5,877,897; 5,796,094; 5,949,331;6,222,447; 6,302,545; 6,396,397; 6,498,620; 6,523,964; 6,611,202;6,201,642; 6,690,268; 6,717,610; 6,757,109; 6,802,617; 6,806,452;6,822,563; 6,891,563; 6,946,978; 7,859,565; 5,550,677; 5,670,935;6,636,258; 7,145,519; 7,161,616; 7,230,640; 7,248,283; 7,295,229;7,301,466; 7,592,928; 7,881,496; 7,720,580; 7,038,577; 6,882,287;5,929,786 and/or 5,786,772, and/or U.S. Publication Nos.US-2014-0340510; US-2014-0313339; US-2014-0347486; US-2014-0320658;US-2014-0336876; US-2014-0307095; US-2014-0327774; US-2014-0327772;US-2014-0320636; US-2014-0293057; US-2014-0309884; US-2014-0226012;US-2014-0293042; US-2014-0218535; US-2014-0218535; US-2014-0247354;US-2014-0247355; US-2014-0247352; US-2014-0232869; US-2014-0211009;US-2014-0160276; US-2014-0168437; US-2014-0168415; US-2014-0160291;US-2014-0152825; US-2014-0139676; US-2014-0138140; US-2014-0104426;US-2014-0098229; US-2014-0085472; US-2014-0067206; US-2014-0049646;US-2014-0052340; US-2014-0025240; US-2014-0028852; US-2014-005907;US-2013-0314503; US-2013-0298866; US-2013-0222593; US-2013-0300869;US-2013-0278769; US-2013-0258077; US-2013-0258077; US-2013-0242099;US-2013-0215271; US-2013-0141578 and/or US-2013-0002873, which are allhereby incorporated herein by reference in their entireties.

Changes and modifications in the specifically described embodiments canbe carried out without departing from the principles of the invention,which is intended to be limited only by the scope of the appendedclaims, as interpreted according to the principles of patent lawincluding the doctrine of equivalents.

The invention claimed is:
 1. A camera module for a vehicular visionsystem, said camera module comprising: a metallic housing comprising ametallic upper housing portion and a metallic lower housing portion; acamera accommodated in said metallic housing, said camera comprising animager circuit board having an imager thereat, said camera comprising alens barrel that accommodates a lens and that protrudes outside saidmetallic housing through an aperture of said metallic upper housingportion; a primary circuit board accommodated in said metallic housing,said primary circuit board having an upper side and a lower side, saidprimary circuit board having an image processor disposed thereat,wherein said image processor processes image data captured by saidcamera, and wherein said image processor is disposed at the lower sideof said primary circuit board and is in thermal conductive connectionvia a thermal element with an inner side of said metallic lower housingportion; wherein an outer side of said metallic lower housing portioncomprises heat dissipating fins; wherein the heat dissipating fins arepresent at the outer side of said metallic lower housing portion at anouter-side location that is juxtaposed with an inner-side location wheresaid image processor is in thermal conductive connection via the thermalelement with the inner side of said metallic lower housing portion;wherein the heat dissipating fins are in thermal conductive connectionwith said image processor; a cooling fan assembly attached at the outerside of said metallic lower housing portion, said cooling fan assemblycomprising an electrically powerable motor that, when electricallypowered, rotatably drives a plurality of fan blades of said cooling fanassembly; wherein said cooling fan assembly, when the motor iselectrically powered, directs airflow along and between the heatdissipating fins of the outer side of said metallic lower housingportion; wherein said camera module is configured to be mounted at anin-cabin side of a windshield of a vehicle so as to have a field of viewthrough the windshield and forward of the vehicle; and wherein saidcooling fan assembly comprises a first exit duct that, when the motor ofsaid cooling fan assembly is electrically powered, directs airflow alongand between the heat dissipating fins of the outer side of said metalliclower housing portion.
 2. The camera module of claim 1, wherein an outerside of said metallic upper housing portion comprises upper heatdissipating fins that are in thermal conductive connection with the heatdissipating fins of the outer side of said metallic lower housingportion.
 3. The camera module of claim 1, wherein said cooling fanassembly comprises a low profile cooling fan assembly that does notprotrude beyond the height of the heat dissipating fins of the outerside of said metallic lower housing portion.
 4. The camera module ofclaim 1, wherein said cooling fan assembly comprises a second exit ductthat, when the motor of said cooling fan assembly is electricallypowered, directs airflow along and between rear heat dissipating fins ofan outer side of a rear portion of said metallic housing, and whereinthe rear heat dissipating fins are present at the outer side of saidrear portion of said metallic housing at an outer-side location that isjuxtaposed with an inner-side location where said imager circuit boardis in thermal conductive connection via another thermal element with aninner side of said rear portion of said metallic housing.
 5. The cameramodule of claim 1, wherein said cooling fan assembly is at leastpartially received in a recessed region of said metallic lower housingportion.
 6. The camera module of claim 1, wherein said cooling fanassembly is detachably attached at the outer side of said metallic lowerhousing portion via one or more fasteners.
 7. The camera module of claim1, wherein electrical connection to said cooling fan assembly is madewhen said cooling fan assembly is attached at the outer side of saidmetallic lower housing portion via terminals of said cooling fanassembly electrically connecting to terminals of said camera module whensaid cooling fan assembly is attached at the outer side of said metalliclower housing portion.
 8. The camera module of claim 1, wherein, whenthe motor of said cooling fan assembly is electrically powered, saidcooling fan assembly directs air axially onto a portion of the heatdissipating fins of the outer side of said metallic lower housingportion, whereby the air flows in a direction along and between the heatdissipating fins.
 9. The camera module of claim 1, further comprising acontroller having control circuitry and associated software, whereinsaid controller controls the motor of said cooling fan assemblyresponsive to one or more sensors.
 10. The camera module of claim 9,wherein the motor of said cooling fan assembly comprises a variablespeed motor, and wherein said controller adjusts speed of the motor ofsaid cooling fan assembly based on the one or more sensors.
 11. Thecamera module of claim 10, wherein at least one of the one or moresensors comprises an ambient light sensor that senses ambient light atthe vehicle, and wherein said controller adjusts the speed of the motorof said cooling fan assembly based on the sensed ambient light at thevehicle.
 12. The camera module of claim 10, wherein at least one of theone or more sensors comprises a temperature sensor that senses atemperature at said camera module, and wherein said controller adjuststhe speed of the motor of said cooling fan assembly based on the sensedtemperature at said camera module.
 13. A camera module for a vehicularvision system, said camera module comprising: a metallic housingcomprising a metallic upper housing portion and a metallic lower housingportion; a camera accommodated in said metallic housing, said cameracomprising an imager circuit board having an imager thereat, said cameracomprising a lens barrel that accommodates a lens and that protrudesoutside said metallic housing through an aperture of said metallic upperhousing portion; a primary circuit board accommodated in said metallichousing, said primary circuit board having an upper side and a lowerside, said primary circuit board having an image processor disposedthereat, wherein said image processor processes image data captured bysaid camera, and wherein said image processor is disposed at the lowerside of said primary circuit board and is in thermal conductiveconnection via a lower thermal element with an inner side of saidmetallic lower housing portion; wherein an outer side of said metalliclower housing portion comprises lower heat dissipating fins; wherein thelower heat dissipating fins are present at the outer side of saidmetallic lower housing portion at an outer-side location that isjuxtaposed with an inner-side location where said image processor is inthermal conductive connection via the lower thermal element with theinner side of said metallic lower housing portion; wherein the lowerheat dissipating fins are in thermal conductive connection with saidimage processor; wherein said imager circuit board is in thermalconductive connection via a rear thermal element with an inner side of arear portion of said metallic housing; wherein an outer side of the rearportion of said metallic housing comprises rear heat dissipating fins;wherein the rear heat dissipating fins are present at the outer side ofthe rear portion of said metallic housing at an outer-side location thatis juxtaposed with an inner-side location where said imager circuitboard is in thermal conductive connection via the rear thermal elementwith the inner side of the rear portion of said metallic housing;wherein the rear heat dissipating fins are in thermal conductiveconnection with said imager circuit board; a cooling fan assemblyattached at the outer side of said metallic lower housing portion, saidcooling fan assembly comprising an electrically powerable motor that,when electrically powered, rotatably drives a plurality of fan blades ofsaid cooling fan assembly; wherein electrical connection to said coolingfan assembly is made when said cooling fan assembly is attached at theouter side of said metallic lower housing portion via terminals of saidcooling fan assembly electrically connecting to terminals of said cameramodule when said cooling fan assembly is attached at the outer side ofsaid metallic lower housing portion; wherein said cooling fan assemblycomprises a first exit duct that, when the motor of said cooling fanassembly is electrically powered, directs airflow in a direction alongand between the lower heat dissipating fins of the outer side of saidmetallic lower housing portion; wherein said cooling fan assemblycomprises a second exit duct that, when the motor of said cooling fanassembly is electrically powered, directs airflow in a direction alongand between the rear heat dissipating fins of the outer side of the rearportion of said metallic housing; and wherein said camera module isconfigured to be mounted at an in-cabin side of a windshield of avehicle so as to have a field of view through the windshield and forwardof the vehicle.
 14. The camera module of claim 13, wherein an outer sideof said metallic upper housing portion comprises upper heat dissipatingfins that are in thermal conductive connection with at least oneselected from the group consisting of (i) the lower heat dissipatingfins of the outer side of said metallic lower housing portion and (ii)the rear heat dissipating fins of the outer side of the rear portion ofsaid metallic housing.
 15. The camera module of claim 13, wherein saidcooling fan assembly comprises a low profile cooling fan assembly thatdoes not protrude beyond the height of the lower heat dissipating finsof the outer side of said metallic lower housing portion.
 16. The cameramodule of claim 13, wherein said cooling fan assembly is at leastpartially received in a recessed region of said metallic lower housingportion.
 17. The camera module of claim 13, wherein said cooling fanassembly is detachably attached at the outer side of said metallic lowerhousing portion via one or more fasteners.
 18. A camera module for avehicular vision system, said camera module comprising: a metallichousing comprising a metallic upper housing portion and a metallic lowerhousing portion; a camera accommodated in said metallic housing, saidcamera comprising an imager circuit board having an imager thereat, saidcamera comprising a lens barrel that accommodates a lens and thatprotrudes outside said metallic housing through an aperture of saidmetallic upper housing portion; a primary circuit board accommodated insaid metallic housing, said primary circuit board having an upper sideand a lower side, said primary circuit board having an image processordisposed thereat, wherein said image processor processes image datacaptured by said camera, and wherein said image processor is disposed atthe lower side of said primary circuit board and is in thermalconductive connection via a thermal element with an inner side of saidmetallic lower housing portion; wherein an outer side of said metalliclower housing portion comprises heat dissipating fins; wherein the heatdissipating fins are present at the outer side of said metallic lowerhousing portion at an outer-side location that is juxtaposed with aninner-side location where said image processor is in thermal conductiveconnection via the thermal element with the inner side of said metalliclower housing portion; wherein the heat dissipating fins are in thermalconductive connection with said image processor; a cooling fan assemblyattached at the outer side of said metallic lower housing portion, saidcooling fan assembly comprising an electrically powerable motor that,when electrically powered, rotatably drives a plurality of fan blades ofsaid cooling fan assembly; wherein said cooling fan assembly is at leastpartially received in a recessed region of said metallic lower housingportion; wherein electrical connection to said cooling fan assembly ismade when said cooling fan assembly is attached at the outer side ofsaid metallic lower housing portion via terminals of said cooling fanassembly electrically connecting to terminals of said camera module whensaid cooling fan assembly is attached at the outer side of said metalliclower housing portion; wherein said cooling fan assembly comprises anexit duct that, when the motor of said cooling fan assembly iselectrically powered, directs airflow in a direction along and betweenthe heat dissipating fins of the outer side of said metallic lowerhousing portion; and wherein said camera module is configured to bemounted at an in-cabin side of a windshield of a vehicle so as to have afield of view through the windshield and forward of the vehicle.
 19. Thecamera module of claim 18, wherein said cooling fan assembly comprises alow profile cooling fan assembly that does not protrude beyond theheight of the heat dissipating fins of the outer side of said metalliclower housing portion.
 20. The camera module of claim 18, wherein saidcooling fan assembly is detachably attached at the outer side of saidmetallic lower housing portion via one or more fasteners.